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The issue you've described sounds very unusual. Both halves of the ball shell include bearings, and should rotate freely on the axle. If you can't see anything obvious that could be jamming it, I would encourage you to contact us directly for some help.

Just to make you aware, dismantling the machine any further than is shown in the User guide could void your Dyson warranty, so we would advise you not to try to remove the ball shell without contacting us for advice.

When you have your DC41 easily to hand, please call the Dyson Customer Helpline on 0800 298 0298 (UK), 1-866-693-9766 (US), 1-877-397-6622 (CA) or 1800 239 766 (AU). Our experts will talk you through some simple troubleshooting checks, and may be able to resolve the issue right over the phone. If not, they can discuss your options for repair.

To attach the cover on your Dyson DC41, first lay it flat on the ground with the handle facing up. Next, place the cover over your filter on the roller-ball located near the brush-roll of the vacuum. Rotate the cover clockwise until you hear 3 clicks and you'll be all set to continue vacuuming.

To help you see this visually please refer to the link below. Specifically, you can look at page 6 under section B.

I hope this was helpful. If you would like further assistance, please feel free to give us a call at 877.750.9239. We have helpful and friendly customer care representatives on the line ready to assist you.

On this model dyson there is a flapper valve that opens when the handle release is engaged. It switches the air flow from the hose to the floor nozzle. They break there all the time, and you have to take it to a dyson repair shop.

I hope this was helpful. If you would like further assistance, please feel free to give us a call at 877.750.9239. We have helpful and friendly customer care representatives on the line ready to assist you.